TECHNOLOGY STORIES BIKE INFO, GEOMETRY ... - Vintage Trek

FORK INSTALLATION INSTRUCTIONS
Top Aheadset cup installation
1. Using a standard headset press install the top bearing
into the frame. Make sure the press engages the
lower bonded insert such that no damage or deformation
occurs to the bonded insert.
Fork bearing installation- Cleaning the parts
1. To properly install the bottom bearing on the steerer
and into the frame, all surfaces must be clean of dirt,
oil, grease, or other residue. The best cleaning agent
is Loktite Kleen ‘n Prime, which not only cleans the surfaces
but will speed the curing of the bonding agent. As
an alternative you can also use acetone, trichlorethylene,
or similar compounds. Do not use paint thinner, gasoline,
or similar compounds which will leave an oily film and
prevent bonding of the Loktite.
2. Clean the contact bearing areas of the steerer, the
lower bearing cup, and both the inside and outside
surfaces of the lower bearing. Once the surfaces are
clean, avoid any contact with your hands, since they
have oil on them.
IMPORTANT- be very careful to avoid any contact of the cleaning agent with the
painted finish of the frame. These cleaning agents remove paint. Also avoid getting
cleaning agents on the bearing seals, which may destroy the bearing grease.
Fork bearing installation
1. Place the steel channel in a vise. Place the Fork
dropout rod in the fork dropouts (Fig. 28) and snug up
the attachment bolts.
Apply a thin layer of
Loktite RC680 on both
the steerer and inside
surface of the bearing.
2. Slide the bearing
on the steerer.
Fork
dropout
rod
Bearing
Steel
channel
3. Slide the bearing
Fig. 28
and steerer, with bearing
above the channel, into the slot of the steel channel
which best fits the steerer.
4. Place the fork dropout rod in the fork dropouts and
secure it by tightening down the hex head bolts and
washers located on both ends of the rod.
5. With the hammer, tap the fork dropout rod until the
bottom bearing is pressed into place, flush against the
shoulder of the steerer.
2002 Trek Technical Manual
Fork (with bearing) installation into frame
1. If needed, install the upper Aheadset cup as in
“Top Aheadset Cup Installation” (see above).
2. With the frame upside down (the bottom bracket
upward), secure the frame in a workstand by the
seatpost.
3. Place the fork dropout rod into the fork dropouts
and snug up the attachment bolts.
4. Apply a thin layer of Loktite RC680 to the inside
of the lower bearing cup and outside of the headset
bearing.
5. Slide the fork into the head tube.
6. We recommend this step be done with two people.
One person supports the frame near the head tube. The
other person, while centering the steerer in the upper
Aheadset cup , lightly taps the fork dropout rod with a
hammer to drive the bearing into the lower cup. While
keeping the fork centered and aligned in the frame,
carefully drive the bearing fully into the bearing cup
in head tube.
7. Install the upper Aheadset parts; bearings, cone
and compression wedge, spacers, stem, and top cap.
8. The frame may be moved, but should not be ridden
yet. Allow 24 hours for the Loktite to fully cure before
riding.
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